Composite fertiliser systems

ABSTRACT

A fertiliser pellet comprising: a first region of a nitrogen-providing fertiliser composition; and a second region adhered to the exterior of the first region, the second region comprising a fertiliser composition capable of providing (a) two or more alkali metal and/or alkaline earth metal nutrients and (b) sulphur.

This invention relates to the composition of fertiliser pellets.

A common way to supplement the nutrients that are available to plants isto treat a seedbed, field or other growing medium with fertiliserproducts in the form of agglomerated pellets. Pelletised products canhave the advantages of being stable, easy to spread using conventionalhorticultural or agricultural machinery, and readily dispensed at adesired application rate.

A wide range of fertiliser compositions are available. The effectivenessof a particular fertiliser composition depends on factors including thetype of plants for which it is used, the state of maturity of theplants, the pre-existing state of the growing medium, and theenvironmental conditions.

Key plant nutrients include nitrogen, phosphorus, potassium, magnesium,calcium and sulphur. In a fertiliser composition these individualnutrient elements may be incorporated through their inclusion in any ofa number of chemical compounds. Although different compounds may includethe same underlying nutrient element the bioavailability of thosenutrient elements may differ depending on the mechanism by which thecompound breaks down. The nutrients' bioavailability may also vary as aresult of other aspects of the fertiliser's chemical or mechanicalformulation. For example, some fertiliser pellets may incorporatecoatings or binders that break down slowly in order to delay the releaseof nutrients, some compounds may rely on microbiota in the growingmedium in order to release their nutrient elements and some compositionsmay make nutrients available in a chelated form so as to improve theiruptake.

In order to provide multiple nutrients a grower may apply multipledistinct fertiliser compositions or alternatively a singlemulti-nutrient fertiliser composition. In order for a multi-nutrientcomposition to be effective its constituent compounds must be insuitably balanced proportions and must be capable of acting effectivelyeven in the presence of the other constituents. This effectiveness mayrely on factors other than the contents of the fertiliser: for examplethe presence of environmental water, heat or certain microbiota. Theeffectiveness on plants of multiple-nutrient fertilisers, particularlywhen dependent on environmental factors, is difficult to predict.However, if a multi-nutrient fertiliser composition is effective then ithas the advantage that it requires only a single spreading operation toapply it to a crop.

Urea (CO(NH₂)₂) is commonly used as a nitrogen fertiliser. Urea can bemade synthetically and then formed into pellets for spreading over acrop. U.S. Pat. No. 5,849,060 discloses using urea as the nucleus for afertiliser pellet, with a coating of, for example, a phosphate orhydroxide.

It is known to form urea into fertiliser pellets and to form limestoneinto pellets for dressing to increase soil pH. This can be done bymixing powdered urea or limestone with a binder and then processing itin a pan pelletiser.

Certain minerals, particularly evaporite minerals, can be used assources of nutrients such as potassium, calcium, magnesium and sulphur.For example, Gypsum can be pelletised and used as a source of calciumand sulphur.

Polyhalite is an evaporite mineral. It is a complex hydrated sulphate ofpotassium, calcium and magnesium of general formula K₂Ca₂Mg(SO₄)₄.2H₂O.Deposits of polyhalite occur in, amongst other countries, Austria,China, Germany, India, Iran, Turkey, Ukraine, the UK and the USA.

Polyhalite has the capacity to be valuable as a source of agriculturalfertiliser. In some prior art processes it has been proposed todecompose natural polyhalite to extract specific nutrients. See, forexample, WO 2013/074328, U.S. Pat. No. 1,946,068 and U.S. Pat. No.4,246,019. However, intact polyhalite is also usable as a fertiliser,being able to supply sulphur, potassium, calcium and magnesium to thesoil.

Mineral polyhalite can be spread in raw, crushed form. That minimisesprocessing costs, but it has a number of disadvantages. Once applied tothe soil the raw mineral takes some time to break down, delaying thebioavailability of its constituents. If applied in chipped form, thepolyhalite tends to be of irregular shape and size, meaning that therecan be difficulties in applying it uniformly, and meaning that it can bedifficult to apply using some types of agricultural spreading machinery.Powdered polyhalite is difficult to spread evenly in an agriculturalapplication, and since polyhalite powder can be hygroscopic itsmechanical properties can vary quickly and radically over time onceexposed to air.

It would be desirable to have a fertiliser product which is readilyspread and provides a number of nutrients in a manner that isparticularly beneficial to plants.

According to one aspect of the present invention there is provided afertiliser pellet comprising: a first region of a nitrogen-providingfertiliser composition; and a second region adhered to the exterior ofthe first region, the second region comprising a fertiliser compositioncapable of providing (a) two or more alkali metals and/or alkaline earthmetal nutrients and (b) sulphur.

Preferably the second region comprises (a) the two or more alkali metalsand/or alkaline earth metals and (b) sulphur.

The first region may comprise more than 30% by weight of nitrogen.

The first region may comprise more than 80% by weight of urea. The firstregion may consist or substantially consist of urea.

The second region may comprise more than 30% by weight of alkali metalsand/or alkaline earth metals, preferably in a form capable of acting asnutrients, most preferably plant nutrients

The second region may comprise more than 10% by weight of each of twoalkali metals and/or alkaline earth metals, preferably in a form capableof acting as nutrients, most preferably plant nutrients.

The second region may comprise more than 10% by weight of each of threealkali metals and/or alkaline earth metals, preferably in a form capableof acting as nutrients, most preferably plant nutrients.

The said alkali metals and/or alkaline earth metals may be or may beselected from the group comprising potassium, calcium and magnesium.

The second region may comprise more than 15% by weight of sulphur. Thesulphur may be in the form of sulphate.

The second region may comprise a mineral powder. The second region maycomprise more than 70% by weight of a mineral powder. The powder may bea powder of an evaporate mineral. The evaporate mineral may bepolyhalite.

The second region may contact the first region over substantially thewhole of its interface whereby it is adhered to the first region. Thesecond region may be adhered directly to the first region. Alternativelyan adhesive or other layer may be present between the first region andthe second region. The second region may coat the first region.

The second region may surround/envelop or substantially surround/envelopthe first region. The second region may constitute the outer surface ofthe pellet.

According to a second aspect there is provided a fertiliser productcomprising a plurality of pellets as set out above.

The average diameter of the pellets may be less than 20 mm, less than 10mm or less than 7 mm. The average diameter of the pellets may be greaterthan 2 mm, greater than 5 mm or greater than 7 mm.

In the pelletised fertiliser product at least 50% of the pellets, andpreferably more than 80% of the pellets, may be pellets as set outabove. Other pellets in the product may have a different composition.

The present invention will now be described by way of example withreference to the accompanying drawing.

FIG. 1 shows a cut-away view of a composite fertiliser pellet.

The fertiliser product to be described below is composed of solidpellets. In a preferred example each pellet comprises a urea core overwhich is a polyhalite layer. FIG. 1 shows an example of such a pellet.The pellet 1 comprises a core 2 of urea. Over the core is a layer 3 ofpolyhalite. The pellets can be spread on crops, on a seedbed or similarto act as a plant fertiliser. The fertiliser can supply potassium,calcium, magnesium and sulphur from the polyhalite layers of thepellets, and nitrogen from the urea cores of the pellets. In otherexamples the core could be of another fertilizer material than urea, aswill be discussed in more detail below.

Urea is a source of nitrogen. Polyhalite is principally a source ofpotassium, magnesium, calcium and sulphur. Studies undertaken by theapplicant indicate that providing fertiliser that has an outer layer ofpolyhalite and an inner region of urea can be particularly beneficialfor plant growth and development with only a single spreading operationrequired. It is believed that this is due to one or more of thefollowing factors. First, the outer polyhalite layer delivers a broadrange of nutrients which support balanced growth in the initial phase ofrelease from the pellets; and then as the outer layer degrades the urearegion is exposed and releases nitrogen. This staggered release ofnutrients is believed to promote accelerated plant growth anddevelopment without the need for separate spreading of distinctfertilisers. Second, whilst sulphur-coated urea fertilisers are alreadyknown, elemental sulphur requires microbial oxidative chemistry to makeit available to plants, whereas polyhalite supplies sulphur already inan immediately available form for plant uptake and metabolism. Third,naturally occurring polyhalite can often contain additionalmicronutrients which are helpful in the early stages of plant growth.

In general a composite pellet 1 of the type shown in FIG. 1 may comprisethe following.

a. A first region 2 acting as a nitrogen fertiliser. The first regionmay, for example, comprise more than 30% nitrogen by weight. The pelletmay be arranged so that the first region is fully or partially coated onits exterior, and therefore not wholly exposed at the outer surface ofthe pellet. Conveniently, less than 50% and preferably less than 20%,less than 10%, less than 5% and most preferably none of the exteriorsurface of the first region is exposed at the exterior of the pellet.b. A second region 3 acting as a fertiliser that provides (i) two ormore alkali metals and/or alkaline earth metals and (ii) sulphur. Thesecond region may, for example, comprise more than 30% alkali metals andalkaline earth metals by weight, and more than 15% or more than 20%sulphur by weight.

Preferably the first region is substantially soluble in or degradable bywater. Preferably the second region is substantially soluble in ordegradable by water. Where the second region comprises powder boundtogether with a binder, the binder may be water-soluble,

In the case where the pellet comprises a core of urea, the urea core maycontain from 50 to 100% of urea by weight, more preferably 75 to 100%,more preferably 85 to 100%. The urea core may additionally contain abinder and/or other constituents. Those constituents may behomogeneously dispersed through the core. Alternatively, the core mayencapsulate a region of a substantially different composition, forexample a non-urea fertiliser.

The core may be of any desired shape, but conveniently it issubstantially spherical. For example, it may have a Wadell sphericity of0.9 or above.

The size of the core may be such that it has a largest dimension lessthan 5 mm, less than 4 mm, less than 3 mm, less than 2 mm or less than 1mm. The size of the urea core may be such that it has a smallestdimension greater than 4 mm, greater than 3 mm, greater than 2 mm,greater than 1 mm or greater than 0.5 mm. The volume of the core may beless than 20 mm³, less than 15 mm³, less than 10 mm³, less than 8 mm³ orless than 5 mm³. The volume of the core may be greater than 15 mm³,greater than 10 mm³, greater than 8 mm³, greater than 5 mm³ or greaterthan 1 mm³. Other dimensions could be adopted.

The core may be formed by any suitable mechanism, for example, in thecase of a urea core it may be formed by prilling or granulation. Methodsof producing urea pellets are well known.

The urea core may be formed by any suitable mechanism, for exampleprilling or granulation.

In the case where the layer 3 comprises polyhalite, the layer 3 maycontain from 50 to 100% of polyhalite by weight, more preferably 75 to100%, more preferably 85 to 100%. In addition to polyhalite thepolyhalite layer may contain a binder and/or other constituents. Thoseconstituents may be homogeneously dispersed through the layer.

Preferably the coating layer 3 entirely covers the inner region or core2. In a bulk product the core may be entirely covered by the outer layerin, for example, more than 90%, more than 95% or more than 99% of thepellets of the bulk product.

Preferably the outer layer 3 is in contact with the majority of theouter surface of the inner region 2. Alternatively there may be anintermediate layer between the inner region and the outer layer. Such anintermediate layer may be a layer of a binder and/or adhesive such asPVA or starch.

Preferably the outer layer 3 is of a substantially uniform thickness.The maximum thickness of the outer layer may be less than 5 mm, lessthan 4 mm, less than 3 mm, less than 2 mm, less than 1 mm or less than0.5 mm. The minimum thickness of the outer layer may be greater than 4mm, greater than 3 mm, greater than 2 mm, greater than 1 mm, greaterthan 0.5 mm or greater than 0.1 mm. The volume of the outer layer may beless than 20 mm³, less than 15 mm³, less than 10 mm³, less than 8 mm³ orless than 5 mm³. The volume of the outer layer may be greater than 15mm³, greater than 10 mm³, greater than 8 mm³, greater than 5 mm³ orgreater than 1 mm³. Other dimensions could be adopted.

The volume of the outer layer may be between 50% and 100% oralternatively between 75% and 150% or alternatively between 100% and200% of the volume of the inner region. Other proportions could beadopted.

The pellet comprising the inner region and the outer layer may be of anydesired shape, but conveniently it is substantially spherical. Forexample, it may have a Wadell sphericity of 0.9 or above. The size ofthe pellet may be such that it has a largest dimension less than 10 mm,less than 7 mm, less than 6 mm, less than 5 mm or less than 4 mm. Thesize of the pellet may be such that it has a smallest dimension greaterthan 6 mm, greater than 5 mm, greater than 4 mm, greater than 3 mm orgreater than 1 mm. The volume of the pellet may be less than 70 mm³,less than 60 mm³, less than 50 mm³, less than 40 mm³ or less than 30mm³. The volume of the pellet may be greater than 20 mm³, greater than30 mm³, greater than 40 mm³, greater than 50 mm³ or greater than 60 mm³.Other dimensions could be adopted.

The size of the pellet and the relative sizes of the core 2 and theouter layer 3 can be selected for best performance in the environmentalconditions and on the crop for which the fertiliser is intended.

In the case of a fertiliser in bulk, the values given above for thesizes, shapes and relationship between the core 2 and the outer layer 3,and for the size and shape of the pellet itself may be mean or medianvalues over the bulk. Alternatively, greater than 50%, greater than 80%or greater than 90% of the particles of the bulk fertiliser may be takento have the requisite value(s).

There could be a coating over the exterior of the polyhalite layer 3.That could, for example, be a sealant (e.g. to resist breakdown of thepellet in transit) or a lubricant (e.g. to assist in spreading of thepellet). The coating could be water-soluble so that it degrades readilywhen the pellet is spread on a crop or growing medium.

As indicated above, polyhalite is a complex hydrated sulphate ofpotassium, calcium and magnesium of general formula K₂Ca₂Mg(SO₄)₄.2H₂O.Polyhalite has a Moh's hardness of around 2.5 to 3.5. Polyhalite can beextracted from natural reserves by mining. Once mined, the polyhalitemay be broken into blocks or chips of suitable size for transport andprocessing. For example, the as-mined rock may be fed to crushers suchas jaw crushers and/or cone crushers in order to yield a chippedmaterial of generally uniform size. It has been found that chips oflargest dimension no greater than around 20 mm and/or of averagedimension between 5 and 10 mm are convenient for transportation from amine. The chips can be transported by conveyor, trucks or any otherconvenient mechanism.

In one example of a method for forming the pellet of FIG. 1, raw orchipped polyhalite is processed to form a polyhalite powder. This maysuitably be done by milling, for example in a ball mill (e.g. acontinuous “Hardinge” ball mill) or more preferably an attritor mill. Inan attritor mill the feedstock is agitated together with freely movinggrinding elements such as steel balls. Air-swept suction may be appliedin order to draw the milled material out of the mill. This allows themilling to be performed as a continuous process if desired, with chippedfeedstock being added to the mill and powder being swept out of the millby gas flow whilst the grinding elements continue to be agitated. Theaverage grain size of the powder resulting from the mill is dependent onvarious process parameters of the milling operation, including the dwelltime of the feedstock in the mill. Conveniently, the mill may bearranged to produce polyhalite powder of a grain size generally around200 μm: for example in the range from 50 to 500 μm or more preferablyfrom 100 to 300 μm. Conveniently at least 50% or more preferably atleast 70% of the mass of the polyhalite powder is composed of grainshaving a grain size, or a largest or average diameter, in one of theabove ranges. The number average grain size of the polyhalite powder maybe in one of those ranges. The grain size may be as measured by means ofa Malvern Mastersizer 2000 or as measured by means of a sieve shaker.

In the next processing stage the polyhalite powder is combined withstarch particles to form a dry homogeneous blend of polyhalite andstarch. This mixing phase is preferably performed so that the polyhaliteand starch are mixed in the absence of free water, since that allows thecomponents to be blended together more easily and effectively. Thepolyhalite and starch may be combined in any suitable mixing device orseries of mixing devices. In one example, the polyhalite and starch arefed separately into a single mixer, which is operated so as to output ahomogeneous blend of polyhalite and starch. That mixer may be arelatively high shear mixer. It may for example be a pin mixer or atwin-shaft mixer. In a second example, the polyhalite and starch may befed separately to a first mixer which performs initial mixing of thecomponents, and the output of that first mixer may then be fed to asecond mixer which mixes them further. In this two-stage process thefirst mixing stage may be performed at relatively low shear and thesecond mixing stage at relatively high shear, or vice versa. The firststage mixer may for example be a ribbon mixer, a pin mixer or atwin-shaft mixer. The second stage mixer may for example be a pin mixeror a twin-shaft mixer. It is advantageous for the or each mixer to beoperated in a continuous process. To achieve that the feedstock:polyhalite and starch as separate feeds or as a partially blended singlefeed, can be fed to one end of the mixer and the agitation process canbe arranged to feed material progressively towards a discharge openingat the opposite end of the mixer. The length of the mixer, the mixingspeed and the agitator (e.g. pin or paddle) design can be selected so asto achieve sufficient dwell time in the mixer that the output from themixture is of the desired homogeneity and/or plasticity: for exampleuntil it is substantially homogeneous. The operating power of the mixercan be controlled to apply the desired level of shear.

The starch may be derived from any convenient source, for example corn,potato, rice, tapioca or wheat. The starch could be a synthetic starch.The starch may consist essentially of chains of amylose and amylopectin.For example the content of the starch feed may comprise at least 50% andmore preferably at least 75% amylose and amylopectin (in total) byweight. The starch may be in powdered form or in granules. Preferablythe starch is of a powder having a grain size generally around 500 μm:for example in the range from 200 to 800 μm or more preferably from 350to 650 μm. Conveniently at least 50% or more preferably at least 70% ofthe mass of the starch powder is composed of grains having a grain size,or a largest or average diameter, in one of the above ranges. The numberaverage grain size of the starch powder may be in one of those ranges.The grain size may be as measured by means of a Malvern Mastersizer 2000or as measured by means of a sieve shaker. The starch acts as a binderto help the polyhalite powder to adhere to itself, thereby increasingthe strength of the polyhalite layer of the eventual pellets. This issignificant because the pellets should preferably be capable ofresisting mechanical breakdown when spread through conventionalagricultural spreaders. The binder also renders the polyhalite powdermore plastic, which aids in the subsequent processing steps.

Thus, in one example of the first mixing stage the polyhalite powder ismixed with particulate starch, under dry conditions and in more or moremixing steps, to form a homogeneous dry blend. Water could alternativelybe added during the first stage, but it is preferred that there is atleast an initial dry mixing stage, performed substantially in theabsence of free water. During the first mixing phase the mixture ispreferable held under conditions under which gelling of the starch isinhibited, for example by keeping the mixture below the gelatinizationtemperature of the starch.

The proportion of starch to be added to the mixture will depend on thenature of the starch being used. The proportion should be selected so asto achieve satisfactory strength in the resulting polyhalite pellets.

In a second mixing stage the pre-blended polyhalite and starch mixtureis mixed with water under conditions that are such as to cause thestarch to gelatinise. Once gelatinised the starch can act to bind thepolyhalite powder together. The process of gelatinisation involves themixture being elevated to a suitable temperature, above thegelatinization temperature of the starch.

In one example of the second mixing stage, water is added to thepolyhalite/starch mixture and the water is mixed together with thepolyhalite and starch at a temperature below the temperature at whichthe starch will significantly gelatinise. Then in a second step thetemperature of the mixture is raised whilst the mixture continues to bemixed, so as to cause the starch to gelatinise. To implement this, theoutput of the first, dry mixing stage can be passed to a first mixerwhere water is added to the polyhalite/starch blend and mixed into theblend, and then the output of that first mixer is passed to a secondmixer in which the temperature is elevated. In a second example of thesecond mixing stage, water is added to the polyhalite/starch mixtureunder temperature conditions that are such that the starch will begin tosignificantly gelatinise when the water contacts the starch. Anysuitable type of mixer or mixers may be used in the second mixing stage.Examples include pin mixers and twin-shaft mixers.

A range of methods may be employed to arrange that the starch iselevated to a sufficient temperature to permit gelatinisation. First,heat may be applied directly to the appropriate mixing vessel. Forexample, the mixing vessel may be fully or partially enclosed with aheating jacket. Or a heating element may be located within the mixingvessel. Second, the water may be heated before being applied to thepolyhalite/starch mixture. In one specific example, the water may beintroduced into the mixing vessel in the form of steam or vapour. Forexample the water as introduced may be at a temperature greater than 50°C. or 60° C. or 70° C. or 80° C. or 90° C. or 100° C. By introducing thewater in the form of steam or vapour, gelling of the starch can beachieved particularly effectively, and it can be easier to achieveuniform combination of the steam or vapour with the starch than ifliquid water is used. Third, the mechanical action of mixing of thepolyhalite and starch can elevate the mixture's temperature,particularly if that mixing is performed with high shear. Each of thesemethods may be used alone or in any combination. For activation of thestarch the mixture should preferably be at a temperature of at least 60°C. or 70° C.

In one preferred example, the first, dry mixing stage is performed withhigh shear so as to elevate the temperature of the mixture, and theoutput from the dry mixing stage is fed directly to a mixer forperforming the second mixing stage. Water as steam or vapour is injectedinto the vessel of that second mixer. These measures may of themselvesintroduce sufficient heat that substantially all the starch in themixture will be gelled. If necessary, the second mixer may be jacketed,and heat applied to the exterior of the mixing vessel of the secondmixer whilst it mixes the polyhalite, starch and water in the secondmixing stage.

The or each mixing vessel in which the second stage of mixing isperformed is preferably substantially enclosed so as to resist theescape of water vapour and to retain heat in the mixture.

Once the starch is gelled, the starch and polyhalite can continue to bemixed to promote intimate binding between the gelled starch and thepolyhalite powder. In a continuous mixing process in which the stockmoves progressively through the mixing chamber, the length of the mixingchamber can be selected so that the material is not discharged until ithas achieved a sufficient dwell time.

Once the polyhalite and gelled starch are sufficiently worked, themixture is processed to cause it to coat previously formed pellets ofurea. One way in which this can be done is to tumble the urea pelletswith the mixture, for example in a horizontal or sloping rotary drummixer which is driven to rotate about its main axis. The moisturecontent of the mixture and the speed of the mixer can be selected sothat the urea pellets are effectively coated with the mixture. The dwelltime of the pellets in the mixer can be selected so that the ureapellets are provided with the desired thickness of polyhalite coating.The axis of the mixer drum can be inclined so that material fed to theupper end of the drum will migrate to the lower end where it can bedischarged. Hot air can be fed to the interior of the drum, for exampleto its lower end, or heat can be applied to the exterior of the drum. Inthis way the composite pellets can be dried so as to harden andstabilise them. The region of the drum to which the wet mixture is fedmay be smooth-walled so that the pellets roll against the interior ofthe drum to round off. The lower region of the drum may be provided withvanes or lifters that protrude inwardly from the walls of the drum.These lift the pellets as the drum rotates and drop them into the warmair in the drum, facilitating drying. On exiting the drum the pelletshave been rounded and dried to a suitable hardness for shipping. Thedryer may be the same apparatus as is used to combine the polyhalitemixture and the urea pellets, or a separate device.

Other methods to coat the urea cores could be used. For example, thepolyhalite mixture could be applied to a pan pelletiser together withthe urea pellets, and the pan pelletiser can then be run to yield acollection of pellets of the appropriate size. Again, the moisturecontent of the mixture and the speed and inclination of the pelletisershould be selected to provide composite pellets of the desired size.

Once the composite pellets have been formed they may then be screened toseparate out under-size and over-size pellets. The undersize pellets canbe returned to the mixer where the urea pellets are combined with thepolyhalite mixture.

Finally the in-size pellets can be cooled and packaged, for example in600 kg bags or 25 kg sacks, or shipped loose for use or furtherprocessing elsewhere. The pellets can be supplied for agricultural use.Eventually they can be spread on a field or other agricultural orhorticultural substrate to act as a fertiliser. The composite pelletsmay be used for purposes other than fertilisation.

Binders other than starch could be used.

Other additives may be included in the pellets. Such additives may oneor more of the following, in any combination:

-   -   a component having the effect of chemically and/or mechanically        stabilising and/or preserving the pellets: for example to        increase their shelf life, reduce their susceptibility to        environmental contaminants or to reduce the likelihood of them        being broken up during spreading (e.g. a pH buffer);    -   a component having the effect of enhancing the fertilising        effect of the polyhalite and/or the urea: for example by        accelerating or retarding the breakdown of the polyhalite in the        field;    -   a component having the effect of protecting or enhancing the        growth of crops by means other than fertilising: for example a        herbicide, fungicide, insecticide, rodenticide, hormone, plant        stimulant or mycorrhizal fungus or spore;    -   a seed: which may be a seed of an angiosperm and/or of a crop        species (e.g. a cereal such as wheat, maize, rice, millet,        barley, oats or rye);    -   a further fertiliser composition in addition to the polyhalite        and the urea;    -   a pigment;    -   a component having the effect of altering soil pH: for example        lime or sulphur.

Such a component may be added at any suitable stage in the process. Forexample it could be combined with the polyhalite powder prior to orduring the first mixing stage as described above, or with the starchprior to the first mixing stage as described above, or with thepolyhalite/binder mix between the first and second mixing stages asdescribed above, or during the second mixing stage as described above,or it could be added to the extruder, or it could be sprayed orotherwise coated on to the pellets before or after drying.

The composite pellets are preferably substantially free from voids, forexample having not more than 1%, 2% or 5% by volume of air.

The process as described above may be used for coating pellets of urea(or another nitrogen fertiliser) with a layer of a mineral other thanpolyhalite, and in particular for coating pellets of urea (or anothernitrogen fertiliser) with pelletising feedstocks composed principally ofone or more evaporite minerals, especially other chloride minerals.These may include any one or more of Anyhdrite, Carnalite, Gypsum,Halite, Kainite, Kieserite, Langbeinite and/or Sylvite. The process isespecially suitable for forming coating layers from feedstocks composedprincipally of minerals that are substantially hygroscopic in recentlypowdered form and/or that have a Moh's hardness in the range from 2 to4. Thus, the outer layer 3 of the composite pellet may be composed ofmore than 80% or more than 90% by mass of any one of the evaporateminerals listed above, or a combination thereof

In examples given above, the internal region 1 is based on urea. Theinternal region 1 may be based on a nitrogen-providing composition otherthan urea. Examples include ammonia-based compositions and othernitrate-based compositions. Preferably the nitrogen composition of theinternal region comprises greater than 20% or greater than 30% orgreater than 40% nitrogen by weight.

The outer region 2 preferably comprises more than 10% by weight of twoor more of potassium, calcium and magnesium. The outer region 2preferably comprises more than 10% by weight of sulphur, and morepreferably more than 15% by weight of sulphur. The sulphur is preferablypresent as sulphate. For manufacture of the outer region it isconvenient if the outer region is an agglomerated powder of one or moreminerals having the requisite composition, but the nutrient componentsof the outer region could be formed synthetically.

Where a property is specified above in respect of a single pellet, thatcriterion may be applied in the case of a bulk pelletised fertiliser as(i) the mean value over the bulk, (ii) the median value over the bulk,or (iii) by more than 50% or more than 80% of the pellets of the bulkfertiliser having the requisite property.

The applicant hereby discloses in isolation each individual featuredescribed herein and any combination of two or more such features, tothe extent that such features or combinations are capable of beingcarried out based on the present specification as a whole in the lightof the common general knowledge of a person skilled in the art,irrespective of whether such features or combinations of features solveany problems disclosed herein, and without limitation to the scope ofthe claims. The applicant indicates that aspects of the presentinvention may consist of any such individual feature or combination offeatures. In view of the foregoing description it will be evident to aperson skilled in the art that various modifications may be made withinthe scope of the invention.

1. A fertiliser pellet comprising: a first region of anitrogen-providing fertiliser composition; and a second region adheredto the exterior of the first region, the second region comprising afertiliser composition capable of providing (a) two or more alkali metaland/or alkaline earth metal nutrients and (b) sulphur, wherein thesecond region comprises a mineral powder, the mineral powder being apowder of polyhalite.
 2. A fertiliser pellet as claimed in claim 1,wherein the first region comprises more than 30% by weight of nitrogen.3. (canceled)
 4. A fertiliser pellet as claimed in claim 1, wherein thesecond region comprises more than 30% by weight of alkali metal and/oralkaline earth metal nutrients.
 5. A fertiliser pellet as claimed inclaim 1, wherein the second region comprises more than 10% by weight ofeach of two alkali metal and/or alkaline earth metal nutrients.
 6. Afertiliser pellet as claimed in claim 1, wherein the second regioncomprises more than 10% by weight of each of three alkali metal and/oralkaline earth metal nutrients.
 7. A fertiliser pellet as claimed inclaim 1, wherein the said alkali metal and/or alkaline earth metalnutrients are or are selected from the group comprising potassium,calcium and magnesium.
 8. A fertiliser pellet as claimed in claim 1,wherein the second region comprises more than 15% by weight of sulphur.9. A fertiliser pellet as claimed in claim 1, wherein the second regioncomprises more than 15% by weight of sulphur in the form of sulphate.10-12. (canceled)
 13. A fertiliser pellet as claimed in claim 1, whereinthe second region contacts the first region over substantially the wholeof its interface to the first region.
 14. A fertiliser pellet as claimedin claim 1, wherein the second region substantially surrounds the firstregion.
 15. A fertiliser product comprising a plurality of pellets asclaimed in claim
 1. 16. A pelletised fertiliser product wherein at least50% of the pellets are pellets as claimed in claim
 1. 17. (canceled) 18.A fertiliser pellet as claimed in claim 1, wherein the first regioncomprises more than 80% by weight of urea.
 19. A fertiliser pellet asclaimed in claim 2, wherein the first region comprises more than 80% byweight of urea.